ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group
ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group - Image 2
ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group - Image 3
ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group - Image 4

ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group

  1. HPC800K01: Early predecessor processor hardware variant, limited spare availability, firmware migration required
  2. HPC800K02: Updated base platform working with processor
  3. AC800M series: Modern ABB controller platform for full‑system migration projects, not direct drop‑in replacement for
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Description

ABB HC800 Control Processor Module for HPC800 / Symphony Plus Harmony DCS SystemABB Group

 

Product Detailed Description

HC800 is a high‑performance DIN‑rail mounted control processor unit serving as core CPU for ABB HPC800 controller within Symphony Plus Harmony distributed control platform, manufactured in Sweden. It executes real‑time process control logic, handles up to 30 000 function blocks, supports mixed connection of S800 I/O and SD series remote I/O subsystems, and provides multi‑protocol industrial communication for field instruments, HMI and upper‑level SCADA systems. This module supports hot‑swap operation, onboard status LED indicators, stop‑push physical switch, and non‑volatile memory for logic retention upon power loss. It can be configured for standalone or redundant dual‑CPU operation for high‑availability critical process plants. Original OEM production is discontinued; available stock includes new‑old‑stock, refurbished and field‑pulled spare units for power, petrochemical and water‑treatment plant life‑extension maintenance projects。

HC800

Technical Parameters

Item Specification
Manufacturer ABB (Sweden)
Model HC800
System Platform Symphony Plus, HPC800 controller seriesABB Group
Product Status OEM Discontinued, spare‑part‑only supply
Processor Freescale ColdFire 32‑bit embedded processor, 256 MHz
Memory 64 MB DRAM, 4 MB ROM, 2 MB NVRAM for logic retention
Max Function Blocks 30 000 blocksABB Group
Task Cycle Minimum 1 ms real‑time control cycle
Communication Ports 2 × Gigabit Ethernet; 2 × RS‑232/RS‑485 serial; 1 × USB front‑panel port
Supported Protocols Modbus‑TCP, Modbus‑RTU, Profibus‑DP, HART, SNTP time synchronization
I/O Backplane Interface Harmony bus for S800 / SD I/O subsystem
Power Supply 24 VDC ±10 %, typical 5 W consumption
Mounting Standard DIN‑rail mounting
Operating Temperature ‑25 °C ~ +55 °C
Storage Temperature ‑40 °C ~ +85 °C
Humidity 5‑95 % RH non‑condensing
Protection Class IP20 for cabinet installation
Dimension 119 mm(W) × 93.6 mm(H) × 200 mm(D)
Weight Approx. 0.5 kg
Certifications IEC 61010‑1, UL, CE, ISA‑S71.04 industrial standard
Programming Standard IEC 61131‑3 (ST, FBD, LD, SFC)

 

Compatibility & Installation Pitfalls

Compatibility

  1. ABB HPC800 controller base unit, Symphony Plus Harmony DCS system backplaneABB Group
  2. S800 I/O modules and SD‑series remote I/O stations
  3. Redundant dual‑CPU architecture supporting hot‑standby mode
  4. ABB Control Builder Plus engineering software; HMI, SCADA and third‑party Modbus host systems

Critical note: HC800 cannot operate standalone. It must pair with matching HPC800 base hardware, correct firmware revision and downloaded project logic. Different hardware revisions are not fully drop‑in compatible without project adaptation.

Installation Pitfalls

  1. Firmware & project version mismatch: Spare hardware will not run plant control logic without downloading matching firmware and complete project database. Mismatched firmware causes initialization failure, communication loss or abnormal control output.
  2. Redundancy configuration risk: When replacing one CPU in dual‑redundant pair, both CPUs must run identical firmware version; version discrepancy breaks hot‑standby synchronization.
  3. Hot‑swap restriction: Hardware supports hot‑swap, but avoid hot‑swap during critical process transient phases; for safety‑related loops, perform replacement under controlled plant condition.
  4. NVRAM data loss risk: Do not remove module while system is powered; unexpected power interruption during removal may corrupt non‑volatile memory logic storage.
  5. ESD vulnerability: Backplane connector and onboard memory circuits are static‑sensitive. ESD wrist‑strap is mandatory during handling; invisible ESD damage triggers random communication drop‑out or logic crash.
  6. DIN‑rail mounting requirement: Ensure firm DIN‑rail clip locking; excessive cabinet vibration will induce intermittent backplane contact failure.
  7. Part‑number verification: Confirm marking HC800. Distinguish from AC800M series CPU modules; they share partial naming but are completely different hardware platforms without interchangeability.

HC800

Standard Operating Procedure (SOP)

  1. Pre‑work: Apply plant lock‑out‑tag‑out procedure for related control segment. For redundant CPU swap, confirm standby CPU is healthy and ready to take over control. Wear ESD anti‑static wrist strap.
  2. Data backup: Backup complete HPC800 project database, record current firmware revision, network IP address configuration and redundant‑mode parameter settings.
  3. Module removal: Record front‑panel LED status before removal. Release DIN‑rail locking latch, extract HC800 processor. Inspect base backplane connector for bent pins or oxidation.
  4. Incoming inspection: Visual check spare unit housing for damage, verify full part‑number marking and hardware revision.
  5. Mechanical mounting: Clip new firmly onto DIN‑rail inside base unit, confirm locking latch fully engaged.
  6. Cabling: Re‑connect Ethernet, serial and USB field cables strictly follow original wiring drawing.
  7. Power‑on commissioning: Restore 24 VDC power supply. If firmware version mismatch exists, execute firmware upgrade / downgrade. Download backed‑up project configuration, set network parameters and redundant‑mode settings.
  8. Functional validation: Observe front‑panel status LED. Verify I/O bus communication with all S800 / SD I/O stations. Check HMI data point refresh, execute loop test for representative control points. For redundant setup, perform standby‑to‑active switch‑over test to confirm fail‑over function. Confirm no system fault alarms.
  9. Documentation: Fill plant maintenance log, archive firmware version and project revision records. Properly package defective removed module. Release lock‑out‑tag‑out permit only after full acceptance test passed.

 

Application Scenarios

‑ Thermal power plant DCS main process control, boiler and turbine auxiliary control ‑ Petrochemical refinery and offshore platform process automation systems ‑ Chemical industry continuous production closed‑loop control ‑ Water‑supply & waste‑water treatment large‑scale distributed control ‑ Legacy ABB Symphony Harmony system preventive maintenance & life‑extension retrofit projects

 

Matching & Supporting Components

  1. controller base unit and DIN‑rail mounting assembly
  2. S800 / SD series I/O modules and remote I/O stations
  3. ABB Control Builder Plus engineering configuration software
  4. Industrial shielded Ethernet and serial communication cables
  5. 24 VDC regulated industrial power supply
  6. Redundancy synchronization cable for dual‑CPU hot‑standby configuration

 

Brand‑Related Alternative & Recommended Models

  1. HPC800K01: Early predecessor processor hardware variant, limited spare availability, firmware migration required
  2. HPC800K02: Updated base platform working with processor
  3. AC800M series: Modern ABB controller platform for full‑system migration projects, not direct drop‑in replacement for

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